Production of yarn from staple fibers



Dec. 27, 1949 J. P. MACKI E PRODUCTION OF YARN FROM STAPLE FIBERS Filed April 7, 1947 5 Shets-Sheet l Inventor JohnBPwri ngle Mack: e

5 Sheets-Sheet 2 Filed A ril 7, 1947 I nvenlor ME M V. e I n I I. n

John Prin y 6 I Dec. 27, 1949 c 2,492,306

PRODUCTION OF YARN FROM STAPLE FIBERS Filed April 7, 1947 5 Sheets-Sheet 3 DDUUUEJ U U slum/2:3;

Dec. 27, 1949 J P. MACKIE 2,492,306

I PRODUCTION OF YARN FROM STAPLE FIBERS Filed April '7, 1947 5 Sheets-Sheet 4 lnvcnfior duh pring'le Mac/ 1 Q Md w :1 llorney Dec. 27, 1949' J, P, MACKIE 2,492,306

PRODUCTION OF YARN FROM STAPLE FIBERS Filed April 7', 1947 5 Sheets- Sheet s Invenlor JohnBPri n lle M a a Ki e y 6 M BM 3 Allowey Pat ented Dec. 27,

s PATENT OFFICE PRODUCTION OF YARN FROM STAPLE FIBERS John Pringle Mackie, Belfast, Northern Ireland,

assignor to Messrs. James Mackie & Sons Limited, Belfast, Northern Ireland, a British com- Application April 7, 1947, Serial No. 739,912 In Great Britain April 24, 1946 12 Claims.

This invention relates to the production of yarn from staple fibres made by cutting continuously spun fibres into staple lengths. Various attempts have been made to break or cut the continuous tow of artificial silk into staple lengths and to draw out the product, form it into a roving and spin it without the interposition of a carding operation. It has not been found possible hitherto to make an entirely satisfactory and uniform yarn in this way, and the method most largely used up to the present has involved a carding operation. For this purpose a continuous tow was formed containing a large number of filaments of artificial silk, and this tow was passed through a machine which cut it into lengths or staple fibre, the cutting generally taking place while the filaments were wet, the staple product being then dried and delivered to textile mills as a package of material with the fibres lying in all directions therein. In. the mills this material was carded and spun by methods similar to those used for natural fibres.

The bunches of cut filaments were often found to be condensed or compacted, and the individual filaments were liable to be twisted and crimped, so that a good deal of breakage of the fibres occurred in carding and preparing the product for spinning. Neps or bunches of short fibre were also formed in the sliver which resulted in imperfections in the finished yarn. The staple fibre might either be fed automatically to the card or spread out more or less evenly by hand on the feed apron, but whichever method of feeding was adopted, considerable variation occurred in the weight of the sliver delivered by the card.

It is the principal object of the present invention to overcome these difliculties by a new method of feeding the material to a carding machine. We have found that if the fibers are fed inan endwise direction into the card, much less breaking of the fibres occurs in carding, and

the resulting sliver is cleaner and substantially free from neps, while the yarn spun from it is smoother and more uniform. It is not possible, however, as a commercial operation, to feed individual filaments or sets of cut staple by hand 2 lengths to be fed end-on in a properly distributed arrangement to the card.

In its broad aspect the invention comprises a method of preparing tows of continuous filaments for spinning into staple fibre yarn, wherein such continuous tows are delivered to a severing device which severs them into successive bunches of staple fibre, these bunches being then presented automatically and in suitably distributed arrangement end-on to a carding machine which forms them into a continuous sliver suitable for drawing and spinning into yarn.

One method of attaining this result is by causing the continuous tows to be delivered to the moving feedlnember of a carding machine and severing them into adjacent successive lengths of fibre thereon by cutting means operating in association with the moving feed member in such manner as to dispose the staple fibres in bunches upon the feed member with the fibres presented end-on to the card.

Various alternative methods may also be used in which for example the cutting into staple lengths is effected before the bunches of fibres all directed longitudinally into the card, and

some method must be adopted to ensure a continuous feed and uniform distribution of the staple fibre. This is effected according to the :resent invention by delivering the artificial silk laments in the form of continuous tow, cutare delivered to the moving feed member, provided that their end-on disposition is preserved as they are fed to the card. The lateral separation of the sets or bunches of fibres is also of importance in ensuring even distribution and avoiding overloading of the card.

The invention also includes apparatus designed to operate according to the methods above indicated.

The invention is illustrated by way of example in the accompanying drawings, in which;

Figure 1, is a side elevation, partly broken away, of the feed apron of a carding machine with means for cutting the fibres into lengths thereon;

Figure 2 is an end view of the mechanism shown in Figure 1, as seen from the front;

Figure 3 is a plan view, drawn to a smaller scale, of the same mechanism;

Figure 4 is a face view, drawn to a larger scale, of a clutch used in the construction of Figures 1 to 3;

Figure 5 is a longitudinal vertical section through the clutch;

Figure 6 is a detail view of the key member inside the clutch;

Figure 7 is a side elevation corresponding to Figure 1 illustrating a modified arrangement, in whichno clutch is required;

.ng them into staple lengths, and causing these 5 Figures 8, 9 and 10 are separate diagrams illus- 7 Y trating alternative methods of cutting the tows into staple lengths and delivering the staple fibres end-on to the card.

Referring first to Figures 1 to 3, a portion of a 'card drum'is indicated diagrammatically at 38, while isa frame supporting a feed apron I2. -This apron is in the form of wooden slats with gaps between them carried by supporting bands 13 at the ends, which run over sprocket rollers l8 on shafts l4 and [5. A shaft H is driven from any convenient source of power (not shown) and carries a sprocket wheel latransmitting the drive to shaft l5 by a chain 13 and sprocket wheel 28 j feed apron carries a gear wheel 2| transmitting.

a drive through idler wheel 22 to a. gear wheel 23 on shaft 24. This shaft carries a roller 25 on which bear heavy rollers 26 supported at intervals in brackets 21 extending upward from frame The tows 28 of continuous filaments are fed over guides 28 to the nip between rollers 25 and 26 and so to the surfaces ofthe feed apron I 2 at the same speed as this apron is moving. The tows are thus laid in parallel strips on the apron as seen in Figure 3. This figure shows four such tows 28 spaced apart over the portion of the feed apron |2 there shown.

The mechanism for cutting the tows into staple lengths as they travel forwards over the feed apron i2 is as follows:

Brackets 3| and 32 suitably connected together across the machine are mounted to slide on the side members of the frame H, and a, transverse beam 33 extends between these brackets, the ends of the beam working in slotted guides 34 on the brackets 3| and 32. The beam carries an electric motor 35 (shown only in Figure 1) which drives a belt 31 carried over pulleys 38 and 38. The pulleys 39 are on spindles 48 supported by the beam 33 and these spindles carry disc cutters 4| which are clamped on their ends. The disc cutters 4| are adapted to pass through slots in a presser plate 42 carried by arms 43 which slide through slots in brackets 44 and 45 projecting from the beam 33. Studs 46 on the arms 43 cause the presser plate to rise with the beam 33 but permit it to stop when the beam descends so that the presser plate may rest by its weight upon and clamp the tows 28 while the disc cutters 4| descend through the slots in the presser plate and through gaps between the slats of the feed apron l2 for cutting the fibres of the tows 28 into staple lengths.

The brackets 3| and 32 are moved to and fro along the frame parallel with the path of the feed apron |2 by heart-shaped cams 58 working between rollers 5| and 52 on the brackets, the cams 58 being carried by a shaft 53 which has a sprocket 54 upon it driven by a chain 55 from a sprocket 56 on shaft H. The shaft 53 is carried in bearings in side extensions 6| of the frame H, and passes through slots in the brackets3| and 32 as shown. Heart-shaped cams such as 58 impart substantially uniform reciprocating movements through rollers 5|, 52 to the brackets 3|, 32 with the beam 33 and disc cutters 4| carried thereby, the speed of movement being such that the disc cutters move forwardly at the same speed as the apron l2, while they are so located that the cutters are over a gap between the slats or the apron when the cutters descend.

The. beam 33 with the disc cutters upon it is moved up and down in the slots 34 of the brackets by connecting rods 57 pivoted on arms 58 projecting from the beam 33, the rods 51 being secured to the straps 59 of eccentrics 8|] on a transverse shaft 62. This shaft is driven so as to turn the eccentrics and to lower and raise the beam 33 during the forward travel of the brackets 3|, 32, but it remains at rest with the beam 33 raised during the return travel. With this object in view the shaft 621s driven by a clutch which makes one revolution and then remains stationary for a revolution. The clutch is shown in detail in Fig- A housing 83 which surrounds the shaft 62 has lugs 64 which are liked by means of screws to the extension 6| of the frame of the machine. The housing has a slot at the top as at 65, and accommodates two hub members 61 and 88, of which hub 61 is fixed by key 89 on the shaft 62, while hub 68 turns freely on the shaft and carries a chain sprocket 18 driven by a chain H from sprocket 12 on the power shaft ll. The hub 68 is held in place by a bush l3 fixed on the end of shaft 62. The shaft is embraced by a saddleshaped key member 14 whose arms are bored to accommodate the springs 15 which project and bear against a shoulder on the hub member 61. The key member 14 has a projecting nib 16 which, when the key is raisedasin Figures 4 to 6, engages in the slot at 65 in the housing 63, while said nib i6 always engages in a. slot at 11 in the hub member 61, thus keying this hub member and its shaft 62 to the housing so long as the key is in its outward position as shown. The fixed housing and the key then hold shaft 82 stationary.

The other hub member 68 is smaller in diameter than hub member 61 and rotates inside a smaller bore of the housing 63. The hub member 68 is also slotted at 18 for engagement by the nib 16 when this is pressed inwards away from the slot 65 in the housing 63. Under these conditions the nib 16 keys the hub 61 to the hub. 68 causing the shaft 62 to be driven by the sprocket wheel 18 on hub 68, while the nib I6 of the key member is held inwards by the smaller bore of the housing and thus prevented from springing outwards until it has completed one turn and is again opposite the slot 65.

For depressing the nib 16 of the key member I4 an arm 88 is provided pivoted at 8| on the extension 6| of the frame, and carrying at its end a sliding plunger 82 pressed downwardly by a strong spring 83 which bears against a collar 84 on the plunger. The top end of the plunger bears a collar 85 which limits its downward movement. The arm 88 has a'lug carrying a cam bowl or stud 86 adapted to be struck and pressed down by a cam projection 81 on a gear wheel 88, this wheel being constantly driven by engagement with a gear wheel 88 on shaft 53. Once in each rotation of the shaft53 therefore, at or about the moment when the heart-shaped cam 58 begins to move the brackets 3| and 32 forwards with the feed apron II, the cam projection 81 depresses the arm 88 for a short time. This causes the plunger 82 to press on the nib 16 of key I4 until the pressure exerted by spring. 83 is strong enough to overcome the pressure of springs I5. The nib 18 and key 14 are then forced inwardly releasing engagement with the slot 65 in the housing and keying the hub members 61 and 68 together for one revolution. The pressure of the plunger 82 on the nib 16 of the key member 14 will generally be' exerted just before the slot 18 in hub member 88 is in its'top position, so that the spring 83 may be exerting a strong pressure on the nib 16 lengths of filaments in bunchesupon said feed member directed end-on toward said carding machine and spaced apart laterally byseveral times their width.

3. Apparatus for forming slivers of staple fibre from tows of continuous filaments comprising a carding machine, a travelling feed member therefor, a severing device and means for supporting it movably over said feed member, means for im-.

parting longitudinal to and fro movements to said severing device parallel to the direction of movement of said feed member, and for imparting intermittent rising and falling movements to said severing device relatively to said feed member, means for delivering a plurality of continuous filament tows in parallel relation and spaced apart laterally on the surface of said feed member, the rising and falling movements of said severing device being timed in relation to its to and fro movements so that said severing device severs'the filaments of said continuous tows during the movements of said severing device in the same direction of travel as that of said feed member, whereby a plurality of laterally spaced bunches of staple fibre are located on said. feed member and delivered end-on to said carding machine.

4. Apparatus for forming slivers of staple fibre from tows of continuous filaments comprising a carding machine, a feed member and means for imparting a travelling movement to the upper surface of said feed member toward said carding I machine, a transverse beam and means supporting it over said feed member such that it can make reciprocating movements parallel with the direction of travel of said feed member, a severing device and means supporting it on said beam such that it can make up and down movements relative to said feed member, mechanismfor imparting reciprocating movements to said beam and for imparting up and down movements to said severing device, means for delivering continuous filament tows to said feed member in positions such that they are severed into staple lengths by said severing device on the descending movements thereof, whereby said staple lengths are presented end-on to said carding machine as bunches of fibres disposed in parallel relation on said feed member.

5. Apparatus for forming slivers of staple fibre from tows of continuous filaments comprisinga carding machine, a feed member therefor having transverse gaps therein at spaced intervals, means for imparting a continuous movement of said feed member towards said carding machine, a severing device and means for traversing it back and forth longitudinally of said feed member-and up and down in relation to said feed member, said traversing means being such that said severing device descends through the traverse gaps in said teed member and returns clear of said gaps during its forward movements, and remains elevated clear of said feed member 'duringits backward movements, means for delivering a plurality of in position such as to pass thereon under said severing device, holding means adapted to clamp said tows on said feed member while being actedupon by said severing device and in position such that the severed lengths remain as separate bunches of staple fibre on said feed memberdirected endon to said carding machine.

6. Apparatus according to claim '5 for forming slivers of staple fibre from tows of continuous filaments wherein said feed member with gaps therein at spaced intervals comprises a feed apron with a series of slats thereon spaced apart longitudinally, and said severing device comprises a plurality of disc cutters each adapted to pass between said slats when severing the filaments of said continuous filament tows.

'7. Apparatus according to claim 5 for forming slivers of staple fibre from continuous filament from tows of continuous filaments, comprising delivering a plurality of such continuous filament tows, wherein the means for imparting up and down movements to said severing device comprises a one-revolution clutch, and power actuated means for driving the same, mechanism operated by said clutch and connected to said severing device adapted to lower and raise again said severing device during one revolution of said clutch, and means for engaging said clutch in alternate revolutions to said power actuated drivingmeans. I

8. Apparatus according to claim 5 for forming slivers of staple fibre from continuous filament tows, wherein said severing device comprises a plurality of disc cutters with means for rotatin the same, and said holding means comprises a presser plate and supporting means therefor adapted to permit said presser plate to rise and fall with said disc cutters, but to stop when resting on said continuous filament tows while said disc cutters continue to descend andto rise again, during the severing of such tows into staple lengths on said feed member.

9. Apparatus according to claim 5 for forming slivers of staple fibre from continuous filament tows, wherein the means for traversing said severing device longitudinally in relation to said feed member comprises a transverse shaft and means for rotating the same, a plurality of heartshaped cams on said shaft and members associated with said severing device. engaging said cams and adapted to impart to and fro traversing means for imparting up and down movements thereto over and into gaps in said feed member, means for delivering a plurality of continuous filament tows spaced laterally of said carding machine upon said feed member, holding means adapted to clamp such tows on said feed memher while being severed by said severing device, said feed member, severing device and holding means being so disposed as to deliver severed le s of staple fibre in laterally spaced bunches all directed on said feed member end-on to said carding machine. 11. A method of formingslivers of staple fibre tows in spaced parallel relation to a severing device, cutting them at spaced intervals lengthwise continuous filament tows to said'feed member I thereofinto successiv -bunches otstaple fibre, and

E ready to cause the nib to drop at once into the slot 18 the moment this is in position to receive the nib. In this way the transfer of the nib from engagement with slot 65 in the housing to its engagement with slot 18 in hub member 68 is effected substantially instantaneously. The arm 80 is freed and the plunger 82 rises again directly after-it has served its purpose, but the key is kept in its inward position by the inner circumference of the housing 63 as hub member 88 turns until it can spring outwardly again and engage with the slot 65 at the completion of the revolution. It will be noted that the sprocket i2 is twice the size of sprocket 10, so that sprocket I and hub member 68 are driven at twice the speed of shaft I'I, while the sprockets 56 and 53 are equal in size, as also are the gears 88 and 99 so that hub member 68 makes two revolutions for each complete turn of the heart-shaped cam 50, and for each operation ofthe plunger 82. Hence, the device described operates as a one-revolution clutch, remaining stationary while the brackets iii, 32, and beam 33 with the disc cutters 46, are moving back clear of the apron, but making one revolution while the beam 33 advances with the apron I2, causing the cutters H to move down and return to their raised position again during this advancing movement. As the cutters are set to register with a gap between the slats of the apron I2 while they advance, they effect the cutting by descending into the gap and rising again from it without fouling the apron. As the clutters descend the presser plate 42 clamps the fibres of the tows 28 against the slats of the apron, so preventing them from being displaced by the rotation of the disc cutters.

In the example of construction illustrated, each disc cutter 4I severs two of the tows 28 at each operation, but this is not an essential feature. The slats of the apron I2 are conveniently spaced at intervals of one inch and the cuts are made at intervals of six inches in the lengths of the tows, as indicated in the plan view, Figure 3. This is only one example of the application of the invention as it will be obvious that the spacing may be varied by suitable choice of the gear wheels and sprockets, and the size of the heart-shaped cams 50.

The disc cutters 4| are constantly driven at a high speed by motor 35 and belts 31. For keeping the edges of the discs sharp it is convenient toprovide pairs of sharpener members 90 carried by a cross beam 9I extending across the machine between the brackets 3| and 32. Each time that the disc cutters rise again after a cutting operation they then engage the sharpeners 90 for a short interval before they move down for the next cutting operation. The sharpeners may be otherwise arranged so as to act on the disc cutters only at longer intervals of time and this device is only illustrated by way of example.

The cutting operation leaves the cut fibres in bunches as at 92, Figure 3, on the apron I2, and as the apron advances these bunches pass between rollers 93 and 94 which will usually be pinned or roughened, and which present the bunches of staple fibre end-onto the surface of the card 30. The card carries them away and forms them into a lap or sliver in the usual manner.

The necessity for the use of the one-revolution clutch can be avoided by arranging the mechanism as shown in Figure 7. The parts identical with those shown in Figure 1 are numbered to correspond with Figure 1, the principal change being in the mechanism which raises and lowers the beam 33.

In this case the shaft I1 drives a shaft 95 through gears and 91 at the same speed as shaft I1, and cranks 98, one at each end of the shaft 95, are connected by rods 99 to the arms 58 projecting from the ends of the transverse beam 33. As the cranks 98 turn they raise the beam 33 so that the cutter M and presser foot 42 are clear of the apron I2 over more than half the rotation of the cranks 98 corresponding to the'backward movement of the brackets 3 I only lowering the cutters and presser foot into the operative position during the forward movement of the apron I2. In

this example, a spring I00 is shown bearing on a collar IOI 0n the rod 43 of the presser foot for augmenting its weight in exerting pressure on the tows 28 when these are clamped on the apron.

The invention is not limited to cutting the tows of continuous filaments on the feed apron itself, and some alternative arrangements are indicated diagrammatically in Figures 8, 9 and 10.

In Figure 8 the continuous tows 28 are fed between rollers I03, I04 to the nip between rollers I05, I00, the latter of which has cutting blades l0! spaced around its periphery at the circumferential distance apart corresponding with the staple length of the fibres to be cut. Bunches of cut fibres I08 slide down over a smooth inclined plate I09, and come to rest on the surface of a feed apron IIO which travels over pulleys III and H2. In the example illustrated the circumferential speeds of the rollers I03 to I06 inclusive are such that the bunches of fibres are fed a little faster than the surface speed of the apron H0, so that the bunches are laid in slightly overlapping positions on the apron. The apron delivers them to the card in this condition, but the distribution is quite satisfactory for feeding purposes.

In Figure 9 the continuous tows 28 are delivered between rollers H3 and H4 to the surface of a travelling apron II5, moving over rollers H6 and II! at each end. The apron has slats in it, as is the case with the feed apron I2 of Figures 1 to 3, and the continuous tows are cut on the apron I I5 by cutter discs 4Ia which may be operated by a mechanism such as that shown in Figures 1 to 3. The severed bunches II8 are delivered to the surface of an ordinary feed apron II9 moving over rollers I20 and I2I, and this apron delivers the bunches to the card in the usual manner.

In Figure 10 the continuous tows are delivered between a pair of rollers I22 and I23 to the surface of a pinned drum I24 rotating in the direction of the arrow so as to carry the tows over the top of the drum as it turns. The drum is slotted at intervals corresponding with the distance apart at which cuts are to be made in the tows, and cutter discs 4), raised and lowered by mechanism such as that shown in Figures 1 to 3, sever the tows into lengths of staple fibre, while the drum I24 rotates. The tows are delivered under another pinned roller I25 to the surface of the licker in or card I20, which carries the fibres away and forms them into a lap or sliver in the usual manner.

I claim:

1. Apparatus for forming slivers of staple fibre from tows of continuous filaments comprising a carding machine, a feed member therefor, an intermittently operating severing device, means i or delivering continuous filament tows to said severing device and means for depositing the several lengths of cut filaments in bunches upon said feed presenting a plurality of such bunches end-0n simultaneously to accruing machine in continufrom tows of continuous filaments as set forth in claim 11, comprising delivering such continuous filament tows in widely spaced relation to a severing device, laying the successive bunches widely spaced apart laterally and overlapping lengthwise on the feed member of a carding machine, and delivering such spaced overlapping bunches endon to the surface of the drum of said carding machine.

JOHN PRTNGLE MACKIE.

' Number REFERENCES CITED The following references are of record in the file of this patent: Y

UNITED STATES PATENTS Number Germany Mar. 5. 1941 

